Bar relay



y 1950 K. w. GRAYBILL 2,515,769

BAR RELAY Filed July 13, 1946 2 Sheets-Sheet l a 2': x) m (D INVENTOR.

KENNETH W. GRAYBILL AT'TORNEY Ki w. GRAYBILL 2,515,769

BAR RELAY 2 Sheets-Sheet 2 2 y W. T n nM mm m .t. VR r w w .9 m o E NOE N N E 25 K T Y o B July 18, 1950 Filed July 13, 1946 Patented July 18, 1950 UNITED STATES PATENT OFFICE BAR RELAY Kenneth 'Wayne Graybill, Elmhurst, Ill., assignor to Automatic Electric Laboratories, Inc., Chicago, 111., a corporation of Delaware Application July 13 1946, Serial No. 683,304

' '3 Claims.

The present invention relates to improvements in switching devices, and more particularly to electrical switching devices .of the electromagnetic relay type, adapted for use in wire .communication systems for selectively setting up connections between various lines embodied therein.

An object of the invention is to provide a device which, by .a single .operation will close a large number of an improved type of electrical contact.

Another object of this .invention is the provision of a. multiple contact or gang type relay in which round wire springs are employed instead of the conventional fiat type springs.

Another object of this invention is to provide a multiple contact relay in which the armature is attached .to the supporting frame by a spring member which is tensioned to retain the armature poles away from the magnet core when the relay is deenergized.

A feature of the invention is the provision of several improved types of contacts formed from the ends of round wire springs which when assembled on relays are arranged so that contacts on adjacent springs are of a diiierent shape to assure that a rubbing motion takes place when a movable armature spring comes into contact with a stationary spring, which results in burnishing both contact surfaces to improve the electrical contact.

Another feature of this invention is the provision of a relay with a plurality of round wire springs uniquely formed to assure that said springs, after being assembled and clamped into position with their respective insulators, will have no tendency to roll or twist out of their proper position in relation to each other and to the armature.

Another feature of this invention is a unique method of control for the movable ends of the stationary round wire springs, which are assembled in such a manner that these springs normally rest in equally spaced serrations in a comb of insulating material, said comb member being so mounted that it is adjustable in relation to another comb, on which rests, in equally spaced serrations, the other round wire spring of each pair of springs. Thus the air gap between the contact metal surfaces of all springs can be regulated when the relay is normal, by the simple method of raising or lowering the first mentioned comb which is held in position by two helical springs and two screws.

Another feature of this invention is to fix the insulatin comb, which supports the spaced-apart movable group of round'wire springs to an armature bracket which is attached to the armature by screws passing through elongated holes in the armature into threaded holes in the bracket to render the bracket, and likewise the insulating comb, movable from side to side, to align all movable round wire springs with all stationary round wire springs, by one operation.

Another feature of this invention is the method of adjusting the air gap between the armature and core. The armature is mounted on a spring reed which is attached to the mounting base and therefore has a fixed normal position, in consequence the core is adjusted in relation to the fixed position of the armature by providingspace in the core mounting holes so that the core may be moved after the mounting screws have been loosened.

Another feature of this invention is to provide two types of wire spring contact surfaces, which are assembled in pairs, one of each type forming a pair, one of which is oval or curved and the other slightly cup or V-shaped, the curved portion of one spring resting in the cup-shaped portion of the other when the relay is energized.

Another feature of this invention is to provide two types of contact points, so formed that when these two types of contacts come together, in response to a movement of the armature, the raised oval portion of the contact on one spring will rest firmly in the cup or V-shaped recess of the second spring of the pair to align these contacts, one with the other and to reduce the possibility-of contact vibration.

The novel characteristics of this invention, the advantages of its particular methods of construction and its operating features will be understood vfrom the following explanation and the reference to the drawings, which consist of fifteen figures on two sheets.

Figure 1 is a top view of a bar relay equipped with thirty-five pairs of make contacts using round wire springs.

Figure 2 is an end view of the relay of Figure 1 taken from the right.

Figure 3 is a bottom view of the relay of Figure 1.

Figure is a view of the armature assembly which includes the spring reed hinge.

Figure 5 is an enlarged view of the side of Figure 11 is a cross section of the insulator of Figure 7 on the line CC. I

Figure 12 is an end view of the insulator of Figure 8.

Figure 13 is a cross section view-of the insulator of Figure 8, on the line AA. I

Figure 14 is a side view of the armature comb riveted to the armature bracket.

Figure is an enlarged view of a portion of the formed ends of the two springs of a pair; showing the relation between the round end and the V cup shaped end.

The embodiment illustrated and described herein consists of a self-contained mechanism including a' U-shaped base plate I of a material having a high reluctance to magnetism, a coil core 3! of magnetic iron extending across the open part of the U-shaped base, a coil 38 wound around the center portion of the core 3|, a U shaped armature 30 of material having a low reluctance to magnetism and two parallel rows of round wire springs;

These round wire springs are clamped near their terminal ends,together with suitable ins'ulators and one side of a H-shaped reed spring, into a spring pile-up. The free contact end of each spring in the top row, such as 69, is curved and plated with contact metal, the free contact end of each spring in the bottom row, such as 5D, is V or cup shaped and plated with contact metal.

The center portion of the U-shaped armature 30 is solidly attached to that side of the H-shaped reed armature spring opposite the side which is anchored in the spring pile-up, the, H-shaped spring being tensioned to maintain the two ends of the -U-shaped armature away from the pole pieces of the core 3 I.

Th'e top row of springs are tensioned against the serrated top edge of an insulating comb II, which maintains the proper spacing between adjacent springs and maintains them in proper hori-. zontal alignment. The bottom row of round wire springs are tensioned against an insulating comb 42 which is mounted on and moves with the armature 30. Horizontal adjustment of comb 42 is provided to enable proper relation to be maintained between springs 'ofthe bottom row and their respectively numbered springs of the top row. Up and down adjustment of either end of thefront member I5 of the stop bracket, which supports the comb I! and the top row of springs, is provided to enable the correct air gap to be maintained between the contact points of the springs in the top row and bottom row. Two leading-in wires are also anchored in the sprin pile-up and supported by the comb I'I. j

A detailed description follows:

In Figure 1. which is a top view of a bar relay with thirty-five pairs of round wire contact springs and one pair of leading-in wires, a very substantial base plate 1! has been provided, upon which the various parts are mounted. Portions of the right and leftsides of this base are turned up at right angles to the base to form side members 2 and 3, these members being extended at one end beyond the bottom part of the base and in shape.

turned at right angles to form lugs 4 and 5 which are equipped with threaded holes 6 and I for mounting the relay on the supporting frame work (not shown) of the telephone switchboard. Two other portions of the base plate 8 and 9 have been turned up at right angles to the base to form mounting brackets for the coil core 3! of the electromagnet. It will be noted that core 3| is longer than the coil 38 and the former is square This square shaped core 3! is provided with two screw mounting holes (not shown) which are larger in diameter than the mounting screws It to provide adjusting means.

I The coil spool ends 32 and 33 of insulating material are placed into position on the core and then staked to hold same in position, after which .the proper amount of wire to form the coil is wound around the core 3! between the two spool heads. Each spool end is provided with a lug or wire terminal 2!).

In Figure 2, an outline of the coil spool end 32 is shown and the outline of the lug or wire terminal 20. In shaping the spool end, a portion of the material is retained to form this terminal or lug 2!) It being a part of the spool head and having a hole to receivethe end of the leadingin wire, provides a rigid terminal on which'to anchor the leading-in wire together with one end of the coil winding. An unique method of supporting the leading-in wires II and I2 has been adopted and can be seen in Figure 1. From the anchoring point on the lug of the spool head. these wires are formed so that they pass through notches in the backstop comb I! and are clamped in the spring pile-up. Leading-in wire 121's clamped in the spring pile-up on a line d rectly underneath leading-in wire II and the terminal end of I2 is therefore directly below end Ila of leading-in wire I I. The ends of these leading-in wires, such as Ila in Figure 1, are formed the same as the ends of the contact round wire springs and the coil control circuit (not shown) will be connected thereto. Y

The back stop bracket fonthe support of the backstop comb I! is composed of two side mem-,

ure 2. The front member I5 is turned down at right angles to the two side members 53 and Hi.

to form a mounting surface for the back stop. insulating comb I? which is attached by a phi-J rality of rivets I8. It will be noted from Figures 1 and 2 that the front member. I5 of the back stop bracket together with the comb I! attached thereto, may be raised or lowered in relation to the base i and armature 313 by the helical springs 25 and the adjusting screws 25. Thus the air gap between the surfaces of theround wire springs 58 and 69 may be regu1ated. One end of the helical spring 25 rests'on the top surface of base plate I and its upper. end is supporting a side member M of the back. stop bracket. The screws 25 pass through holes.

in member I5, through the hollow center of the helical springs and into threaded holes in the base I.

In the end View Figure 2, it will be noted that the roundv wire springs til of the top row are clamped near one end in the spring pile-up and resting near their free end on the insulating back stop comb Ii, which as previously mentioned, is attached by rivets if! to the front member I5 round wire contact springs 50 pass diagonally through the moulded insulators of the sprin pile-up and are firmly clamped therein. These bracket 43, thus the bracket 43 together with insulating comb 42 can be moved from left to right and vice-verse. to move the comb 42 together with the lower row of round wire springs 50 to align these springs with the respectively numbered springs in the top row. The adjusting feature for the air gap between the armature 3i] and coil core 3!, can be seen in Figure 2. It will be noted that the two ends of the armature comb bracket i3, extend to the left and right (as seen in Figures 1 and 2) beyond the edge of the cut away portion of base i and therefore comes to rest, when the coil is deenergized, on the top surface of the base plate I, this limits the downward movement of armature on under pressure of armature reed spring 40 and results in a fixed normal position for the armature Bil. The core 33 is therefore adjust ed in relation to the position of armature 30, by loosening the two screws it) near the ends of core 3! and moving these ends either up or down. The screws IE1 pass through enlarged holes in ends 3! of the core to permit this adjustment.

Figure 3 is a bottom view of the relay of Figure 1 disclosing certain of the novel features. The lower part of the cut away portion of the base i can be noted. This is wide enough to allow free movement of that side of the armature which is attached to the edge of the cut away portion by the armature spring as. Two portion of this s ring so can be seen in Figure 3. These are also seen in Figure 4, being the portions between the elongated hole 48 and the edges 46 and 41. The air spaces 34, in Fig-- ure 3, it will be noted, are narrower than the air space 35 and while this construction allows perfect freedom or movement up and down, it limits an end thrust movement which might be caused accidentally. The circles 35 represent embossed portions which furnish slight projections (not shown) on the opposite. or upper side of the base plate l, to form guides to prevent any end to end movement of the armature reed spring 40 when same is assembled in the spring pile-up, holes 65 and 5% being provided in spring 40 to receive the raised projections. Due to the fact that the screws 28 pass through elongated holes in the armature 53 to threaded holes 55 in the comb bracket 43, 'ahole 39 is provided as a guide for instantly determining the normal setting of the comb bracket 4's in relation to either side of the armature 3% prior to the assembly of.the armature and its armature reed spring 40 onto the base plate I.

It should be noted that the armature 38 is longer than the coil 38, and that a section has been cut away from its upper edge (as seen in Figures 3 and 4) from point 44 to 45, leaving the two end sections far enough apart to completely span coil 38. As previously stated, the core ends extend beyond the ends of the coil 38 and when the coil is energized, one section of the armature 39 comes in contact with one pole of the magnet core 3? and the other section of the armature comes into contact with the opposite pole of the core 31. At points 4| (Figure 4) small non-adjustable residuals are fixed to the armature 3D to perform the usual function of preventing the armature from sticking to the pole pieces after the coil has been de-energized.

Figure 4 shows a top View of the armature assembly including the armature comb bracket 43 and the armature reed spring 40. One portion of the spring is riveted to the armature by a plurality of rivets 49 and another portion is assembled in the spring pile-up and held rigid to the base I. It serves as a hinge for the up and down movement of the armature and therefore the armature does not require one of the ordinary iorrns of pivot mounting. The spring tension restores the armature to normal when the coil is de-energized .and no other armature restoring arrangement is necessary. The special construction, comprising two cut away portions. leaving a narrow neck between points 46 and 41 together with the elongated hole 48 provides satisiactory operation as well as considerable ruggedness to guard against damage which might be caused by careless handling.

Attached to the armature and near its center. is the right angle shaped bracket 43 to support the armature comb 42. An end view of bracket 43 can be seen in Figure 2, it being attached to the armature by a plurality of screws 28. It should be noted that the bracket 43 has threaded holes 55 to receive the screws 28, which pass through elongated holes in the armature to provide adjusting means. The armature comb 42 (shown in Figure 14) is attached to bracket 43 by a plurality of rivets 5S seen in Figures 4 and 14. Comb 42 is serrated on its top edge to space apart and form a back stop against the spring pressure of all of the round wire springs, such as Ell, which comprise the lower half of all the sets of springs.

Figure 5 is a side view of one of the round wiresprings 50 which are assembled, as seen in Figure 2, to form the bottom row of thirty-five, securely clamped near their rear ends in the spring pile-.

up by means of moulded insulators i l and 81 and resting near their contact ends on the comb 42 which is moveable with the armature. A portion 5! of one end of this spring 50 is formed into a shape and plated with contact metal, such as silver or the like, to provide a rare metal contact surface. The relation of the V-shaped end to the curved portion of its respectively numbored spring in the top row, will be seen in Figure 15.

Figure 6 is a side view of one of the round wire springsv 69 which are assembled, as seen in Figure 2, to form the top row of thirty-five, securely clamped near their near ends in the spring pile-up with the moulded insulators and resting near their contact ends on the comb H which is held firmly in position by the rigid, although adjustable back stop bracket. A portion SI of one end of this spring 553 is curved and also plated with contact metal.

It will be noted that a section 52 and 62 of these round wire springs has been .oiiset to a distance of approximately three times their diameter to form curved portions. These portions fit into the grooves and circular depressions in the moulded insulator ii and serve to prevent any inclination to twist or roll when the complete spring pile-up is securely clamped to the base plate 1 by the clamping plate 2i and three clamping screws 21. It will be noted that another section of each round wire spring, i. e., sections 53 and 63 are bent slightly and the end portion'is tinned and formed into a suitable terminal to which the conductors (not shown) of the incoming lines and trunks may be attached. The two portions, 53 and 63, have been formed so that their ends are approximately nine degrees off of a line along the main portion of the spring, to give the result as seen in Figure 2 which has the advantage of providing more space for the incoming and outgoing trunk conductors and also additional installation facilities. Alternate springs in each row are bent in opposite directions Figure '7 is a view of one side of the moulded insulator 7! showing the grooves in that side, as H3 and semi-circular depressions as l l I. It will be seen from the cross sectional view Figure 11 'that both sides of insulator H are similarly equipped with grooves and circular depressions to accommodate the two rows of round wire springs with their offset portions, one row of springs, such as 513, assembled on one side and the second row of springs, such as 60, on the opposite side. Three holes l2, l3, and M pass through the insulator H to accommodate theclamping screws 21. Two recesses, Ti and 18, have been provided to accommodate the bosses 81 and 88 on insulator 8! to insure alignment. Two other recesses are provided, Ill! and H32, which can also be seen in Figure 10 to accommodate bosses i3! and I32 on insulator 8!. Two additional recesses i9 are provided which serve no function in connection with the assembly, but are so arranged as to provide space for the ends of two screws (not shown) which will be used to mount the relay on the supporting frame (not shown). The cross sectional view Figure 10 along the line BB of Figure 7 shows the depressions I! and I62 which are arranged to accommodate bosses l3! and I32, a cross section of these being shown in Figure !3.

Figure 8 is a view of the moulded insulator 8i which is constructed in such a manner that its bosses fit the depressions in insulator H as described and the two form a unit for the correct alignment of thirty-five pairs of round wire contact springs and one pair of leading-in wires. Three holes 82, 83, and 84 are provided in insulater 8! to accommodate the clamping screws 21. Two round depressions 89 are provided in one face of insulator 8| to accommodate the two bosses. (not shown) on the top surface of the.

base plate i. The bosses have been formed by a. punch operation leaving a depression 36 which can be seen in Figure 3.

Figure 14 is a front view of the armature comb 42 attached by a plurality of rivets G to the armature comb bracket $3. This comb is of insulating material and the spaced apart notches or serrations retain each round wire spring in proper relation to the adjacent spring or springs. An end View of the armature bracket 43 may be seen in Figure 2. It will be noted that this bracket 4'3 is attached to and moves with the armature 39, being adjustably attached by the screws 28 and the spring washers 29.

Figure 15 is an enlarged view across the contact portion of the ends of one pair of springs, such as stand 6! The contact end of armature or moveable spring 55!, as previously ex plained, is formed into a V or cup shaped end and when the coil is energized and the armature moves spring 50 upwards (as viewed in Figure 15), the inside surfaces Iii! and I52 of the V come into contact with the contact metalled surfaces I53 and i5 5 on two sides of the wire. It will be seen from Figure 2 that when the armature stroke commences the V-shaped portion of wire 58 makes contactwith the curved surface of wire 60 and as the armature continues its movement for a certain period of time after actual contact is made, the V portion is forced upwards carrying with it the end of spring 60 whose curved contact metal end slides along the inside surfaces of the V-shaped end 5! burnishing both surfaces and when the armature '30 has completed its stroke, curved portion 6| will be firmlv resting in the cup-shaped end 5| of spring 5!! and the downward tension of spring 68, which has been lifted from its supporting comb 42, assures a satisfactory electrical contact. In addition, as the curved portion BI is resting in the V portion 5|, perfect alignment is assured and contact vibration is reduced to a minimum.

This is a simple, rugged, and powerful relay and when a current of proper voltage is applied in accordance with the coil winding, it will operate to lift its armature to close the air gap between the two core poles and the two end sections of the armature and at the same time raising the armature comb with thirty-five round wire springs to make contact with thirty-five stationary round wire springs to close thirty-five electrical contacts. While 35 pairs of springhave been described in this embodiment, it should be understood that different numbers of springs may be used, and that other minor changes may be made without departing from the spirit of the invention.

What is claimed is:

1. In a switching device, a base plate, an arma ture movably attached to said base plate, a pair of rows of round wire springs, a first insulating member mounted on said armature and movable therewith for supporting one row of said springs, a bracket having two arms and a base portion, means for rigidly securing the base portion of said bracket to said base plate, a second insulating member supporting a second row of said round wire springs and attached to the free ends of said two arms of said bracket, two helical springs positioned between the free ends of said two arms and said base plate, and two screws extending through said two arms and said springs and threadedinto said base plate for adjustably positioningthe free ends of said arms and said second insulating member to change the relation between the said first and said second rows of round wire springs.

2. In a multi-contact relay, a frame, an armature movable with respect to said frame, an elec tromagnet mounted on said frame for moving said armature in one direction, a spring assembly secured to said frame and having a first and a second row of round wire springs secured therein, a bracket having a base portion secured in said spring assembly and having two arms each hav ing a free end, an insulating combsecured to said free ends of said arms and having notches in which the free ends of said first row of wire springs rest; a, pair of manually adjustable means one at each free end of said armsv interconnecting both the free ends of said arms and said frame for moving said arms, said comb and the free ends of said first row of springs towards or away from said armature and said second row of springs, a second bracket, a second insulating,

comb secured to said second bracket and having notches in which the free ends of said second row of wire springs rest, means for securing said second bracket and said second insulating comb to said armature, said last means permitting manual adjustment of said second bracket and second insulating comb to move said second row of wire springs at right angles to the movement of said armature to aline the second row of springs with said first row of springs.

3. In a multi-contact relay having an armature, a first row of passive round wire springs, a

" second row of movable round Wire springs, a

bracket having two arms each having an adjustable free end, an insulating comb secured to both free ends of said arms and having notches for positioning the free ends of said first row of passive springs, a manually adjustable means located at the free end of each of said arms for manually adjusting said first row of passive springs toward or away from said second row of movable springs, a second bracket, a second insulating comb secured to said second bracket and having notches for positioning the free ends of the second row of movable springs, manually adjustable mounting means for securing said second bracket and said second comb to said armature and for adjusting said second row of movable springs, said second bracket and said second comb in a direction parallel to said first row of passive springs to aline the second row of movable springs with said first row of passive springs,

10 and an electromagnet for operating said armature to cause said second row of movable springs to engage said first row of passive springs.

KENNETH l/VAYNE GRAYBILL.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 808,957 Varley Jan. 2, 1906 1,003,338 Coleman Sept. 12, 1911 1,133,787 Babcock Mar. 30, 1915 15 1,521,591 Beck Jan. 6, 1925 1,737,264 Newman Nov. 26, 1929 1,954,758 Reisner Apr. 10, 1934 2,069,171 Merkel Jan. 26, 1937 2,096,054 Miller 1 Oct. 19, 1937 2 2,135,832 Obergfell Nov. 8, 1938 2,137,503 Obergfell Nov. 22, 1938 2,323,961 Zupa July 13, 1943 2,338,365 Thorp et a1. Jan. 4, 1944 2,339,610 Baker Jan. 18, 1944 25 2,374,017 Inglehart et a1. Apr. 17, 19 15 FOREIGN PATENTS Number Country Date 200,132 Great Britain July 2, 1923 

